Structural subfloor product and method of manufacturing same

ABSTRACT

A flooring product includes a first oriented strand board layer, an acoustic barrier layer, and a second oriented strand board layer, where the acoustic barrier layer is secured between the first and second oriented strand board layers to form the flooring product. The plurality of flooring products can be positioned adjacently to comprise a complete flooring assembly. Such a flooring assembly can be facilitated by including features along edges of the flooring product for securing or engaging one flooring product to adjacent flooring products. For example, the flooring product can be arranged with one edge as a tongue and an opposing edge as a groove, where the tongue of one flooring product can be fitted into the groove of an adjacent flooring product to secure or engage the two flooring products together. In another example, edges of the flooring products can be arranged to form lap joints upon engagement.

RELATED APPLICATION

This application claims priority to U.S. patent application Ser. No.15/490,422, titled “Structural Subfloor Product and Method ofManufacturing Same,” filed on Apr. 18, 2017, which claims priority toU.S. patent application Ser. No. 15/150,792, titled “Floor Product andMethod of Manufacturing Same,” filed on May 10, 2016, now U.S. Pat. No.9,771,726, which claims priority to U.S. Provisional Patent ApplicationSer. No. 62/163,201, titled “Floor Assembly System and Method forAcoustic Barrier,” filed on May 18, 2015, and U.S. Provisional PatentApplication Ser. No. 62/252,125, titled “Floor Assembly System andMethod for Acoustic Barrier,” filed on Nov. 6, 2015, all of which areexpressly incorporated by reference herein in its entirety.

FIELD OF INVENTION

The present disclosure generally relates to systems and methods forforming barriers to the propagation of acoustic energy. Morespecifically, the present disclosure relates to multi-layered productsand methods of manufacturing and assembling such multi-layer productsfor use as flooring that facilitate forming barriers to the propagationof acoustic energy that meet or exceed building code requirements astested by a Sound Transmission Class protocol and as tested by an ImpactInsulation Class protocol.

BACKGROUND

It is common to create barriers to the transfer or propagation ofacoustic energy (e.g. noise) from one location to another. Noisegenerated in one location may be unwanted and unwelcomed in an adjacentlocation. One common situation where it is desirable to control acousticenergy is in enclosed structures that house multiple groups of peoplesuch as multi-family residential and multi-tenant commercial buildings.Specifically, in a multi-family residential apartment building,condominium building, or hotel, occupants have expectations that theycan enjoy the comfort of their residence, offices, and other such spaceswithout disturbances caused by noise generated by adjacent neighbors.

As will be understood, in a multi-family residential building, forexample, noise can propagate from one apartment to an adjacent apartmentthrough the walls separating apartments located on the same story of thebuilding and through the floor/ceiling separating adjacent apartmentslocated on different stories of the building. With regard to noisepropagating through a floor/ceiling of adjacent apartments, the noisecan be “air-borne” (which can be measured by standardized SoundTransmission Class testing) or caused by “impact” (which can be measuredby standardized Impact Insulation Class testing). Air-borne noise istypically generated by occupants conversing, televisions, stereos, etc.Impact noise is typically generated by objects impacting the floor ofone apartment and propagating to the apartment below. For example, itemsdropped on the floor, or occupants walking with hard-soled shoes on woodor tiled flooring can generate unwanted impact noise in the apartmentbelow.

For current multi-occupant buildings, builders commonly use acementitious underlayment product such as gypsum concrete (sometimesreferred to as Gyp-Crete®) to create acoustic dampening between adjacentstories of the building. Cementitious underlayment products have somesound reduction properties; however, the use of cementitiousunderlayment products and other similar products pose significantchallenges for builders. One significant issue is that such products areapplied as a wet product (e.g., poured as a thick fluid onto a subfloor)into an otherwise dry environment (e.g., a wood framed building). Whensuch a wet product is applied to a dry environment, the moisture canadversely affect the building process. Issues such as warping of woodenelements, splashing onto unintended surfaces, etc. are common.Furthermore, introducing moisture into any environment increases thechances of mold growth in the environment, which is always an unwantedcondition. Another issue is that the application of any wet producttypically requires a drying, curing, or setting period following thepouring or application of the wet product. Such periods can cause delaysin construction and complicate the planning and project managementbetween various contractors and workers. An additional issue withpouring processes such as applying cementitious underlayment products isthat the pouring processes can be limited by weather conditions such asambient temperature. Both high and low temperatures can negativelyaffect the pouring of cementitious underlayment products, and thus,create delays and unpredictability in the construction processes.

It would be advantageous to develop products, assemblies, systems andmethods for facilitating the constructing the floor/ceiling structure ofmulti-occupant buildings that provide for acoustic controllingproperties and overcome the limitations of using prior art techniquesand products such as cementitious underlayment products.

SUMMARY

In one embodiment, a flooring product includes a first oriented strandboard layer, an acoustic barrier layer, and a second oriented strandboard layer. The acoustic barrier layer is secured between the firstoriented strand board layer and the second oriented strand board layerto form the flooring product. The flooring product can be arranged suchthat a plurality of flooring products can be positioned adjacently tocomprise a complete flooring assembly for a portion of a room, theentire room, or a story of a building.

A flooring product can be dimensionally arranged such that the flooringproduct can be efficiently transported from one location to another andefficiently installed during construction of a building. For example,the flooring product can be arranged so that a single workman or a pairof workman can efficiently transport the flooring product from a storageor staging area to the installation location. Select exemplaryembodiments include flooring products that are dimensionally arranged asa four foot by eight foot flooring product, a two foot by eight footproduct, and so on.

The flooring product can be arranged with features that facilitatesecuring or engaging one flooring product to another adjacent flooringproduct to form a flooring assembly. For example, the flooring productcan be arranged to form a tongue and groove joint where one edge of eachflooring product can be arranged as a tongue and an opposing edge of theflooring product can be arranged as a groove. Thus, the tongue of oneflooring product can be fitted into the groove of an adjacent flooringproduct to secure or engage the two flooring products together.

In another embodiment, the flooring product can be arranged to form alap joint where one edge of each flooring product can be arranged as atop lap portion and an opposing edge of the flooring product can bearranged as a bottom lap portion. Thus, the top lap portion of oneflooring product can be secured to or engaged with the bottom lapportion of an adjacent flooring product to secure or engage the twoflooring products.

In another embodiment, flooring products can include edges that arearranged for tongue and groove joints as well as edges arranged for lapjoints. For example, in a two foot by eight foot flooring product, oneeight foot edge can be arranged as a tongue, the opposite eight footedge can be arranged as a groove, one two foot edge can be arranged as atop lap portion, and the opposite two foot edge can be arranged as abottom lap portion. In such an arrangement, a plurality of flooringproducts can be positioned such that adjacent flooring products can besecured or engaged by tongue and groove joints along the eight footedges and secured or engaged by lap joints along the two foot edges. Aplurality of flooring products so secured or engaged can form a flooringassembly that forms a continuous floor for a portion of a room, anentire room, a portion of a story of a building, or the entire story ofa building.

In another embodiment, a method of manufacturing a flooring productcomprises the steps of preparing a first surface of a first orientedstrand board, preparing a first surface of a second oriented strandboard, and preparing a first surface and second surface of an acousticbarrier layer. The method further comprises the steps of applying anadhesive to the first surface of the first oriented strand board, andapplying an adhesive to the first surface of the second oriented strandboard. The method further comprises the steps of placing the firstsurface of the first oriented strand board in contact with the firstsurface of the acoustic barrier layer, and placing the first surface ofthe second oriented strand board in contact with the second surface ofthe acoustic barrier layer. In an alternative example, adhesive can beapplied to the first side of the acoustic barrier layer or the secondside of the acoustic barrier layer to facilitate the manufacturing of aflooring product.

In another embodiment, a method of assembling a flooring product duringconstruction of a building includes the step of providing a firstoriented strand board, a second oriented strand board, and an acousticbarrier layer. The method further includes the step of securing thefirst oriented strand board, the second oriented strand board, and theacoustic barrier layer to a truss system. Optionally, the first orientedstrand board, the second oriented strand board, and the acoustic barrierlayer can be provided as a premanufactured or prefabricated composite orassembly, where the acoustic barrier layer is secured between the firstoriented strand board and the second oriented strand board usingadhesives or mechanical fasteners. Alternatively, the acoustic barrierlayer can be secured between the first oriented strand board and thesecond oriented strand board during the construction of the buildingusing adhesives or mechanical fasteners.

In another embodiment, a method of assembling a flooring assembly duringconstruction of a building includes the step of installing a pluralityof flooring products comprising a first oriented strand board, a secondoriented strand board, and an acoustic barrier layer, where suchflooring products are installed until the flooring for a story of thebuilding is complete. The method further includes the step ofconstructing the framing for that story of the building (i.e., the wallsthat define the rooms and other areas of the story) on top of installedflooring assembly. Each flooring product can be assembled on site inadvance of installation into the flooring system, or alternatively, theflooring products can be provided as premanufactured composite andtransported to the worksite for installation into the flooring system.

In another embodiment the combination of a first oriented strand board,a second oriented strand board, and an acoustic barrier layer onceinstalled meets or exceeds building code requirements as tested andmeasured by a Sound Transmission Class protocol and as tested andmeasured by an Impact Insulation Class protocol.

BRIEF DESCRIPTION OF THE DRAWINGS

In the accompanying drawings, structures are illustrated that, togetherwith the detailed description provided below, describe exampleembodiments of the disclosed systems, methods, and apparatus. Whereappropriate, like elements are identified with the same or similarreference numerals. Elements shown as a single component can be replacedwith multiple components. Elements shown as multiple components can bereplaced with a single component. The drawings may not be to scale. Theproportion of certain elements may be exaggerated for the purpose ofillustration.

FIG. 1 schematically illustrates an exemplary perspective view of aflooring product.

FIG. 2 schematically illustrates an exploded view of the flooringproduct of FIG. 1.

FIG. 3 schematically illustrates a cross-sectional view taken of theflooring product of FIG. 1 taken along the line shown in FIG. 1.

FIG. 4 schematically illustrates an exemplary perspective view of aflooring assembly comprised of a plurality of flooring products.

FIG. 5 schematic illustrates framing constructed on top of a flooringassembly.

FIG. 6 schematically illustrates an exemplary perspective view of aflooring product that includes tongue and groove features.

FIG. 7 schematically illustrates an exploded view of the flooringproduct of FIG. 6.

FIG. 8 schematically illustrates a cross-sectional view taken of theflooring product of FIG. 6 taken along the line shown in FIG. 6.

FIG. 9 schematically illustrates a cross-sectional view of two flooringproducts of FIG. 6 engaged via a tongue and groove system.

FIG. 10 schematic illustrates a cross-sectional view of the flooringproduct of FIG. 6 with additional layers engaged with the flooringproduct.

FIG. 11A-11D schematically illustrate adhesive patterns on an orientedstrand board layer of the flooring product of FIG. 6.

FIG. 12 schematically illustrates a cross-sectional view of a flooringproduct with tongue and groove features and the acoustic barrier layerextending into the groove feature.

FIG. 13 schematically illustrates a cross-sectional view or the groovefeature of the flooring product of FIG. 12.

FIG. 14 schematically illustrates a cross-sectional view of two flooringproducts of FIG. 12 engaged via a tongue and groove system with theextending acoustic barrier layer of one flooring product engaged withthe other flooring product.

FIG. 15 schematically illustrates a cross-sectional view of a flooringproduct that includes lap joint features

FIG. 16 schematically illustrates a cross-sectional view taken of theflooring product of FIG. 15 taken along the line shown in FIG. 15.

FIG. 17 schematically illustrates a cross-sectional view of two flooringproducts of FIG. 15 engaged via a lap joint system.

FIG. 18 schematically illustrates a cross-sectional view of a flooringproduct with lap joint features and the acoustic barrier layer extendinginto the lower lap joint feature.

FIG. 19 schematically illustrates a cross-sectional view of two flooringproducts of FIG. 18 engaged via a lap groove system with the extendingacoustic barrier layer of one flooring product engaged with the otherflooring product.

FIG. 20 schematically illustrates a perspective view of a flooringproduct with two opposing profiled edges and the acoustic barrier layerextending beyond the profiled edges.

FIG. 21 schematically illustrates a front elevation view of the flooringproduct of FIG. 20.

FIG. 22 schematically illustrates a front elevation view of two flooringproducts of FIG. 20 positioned adjacently such that the acoustic barrierlayers of the two flooring products are engaged.

FIG. 23 schematically illustrates a front elevation view of thearrangement of the pair of flooring products of FIG. 22 with a finishedflooring layer positioned on top of the pair of flooring products.

FIG. 24 schematically illustrates a front elevation view of a flooringproduct with profiled edges, tongue and groove features, and theacoustic barrier layer extending beyond the tongue feature in into thegroove feature.

FIG. 25 schematically illustrates a front elevation view of two flooringproducts of FIG. 24 engaged via a tongue and groove system with theextending acoustic barrier layer of one flooring product engaged withthe other flooring product.

FIG. 26 schematically illustrates a front elevation view of thearrangement of the pair of flooring products of FIG. 25 with a finishedflooring layer positioned on top of the pair of flooring products.

FIG. 27 schematically illustrates a perspective view of another flooringproduct with a pair of opposing profiled edges and the acoustic barrierlayer extending beyond the profiled edges.

FIG. 28 schematically illustrates a perspective view of a flooringproduct with four profiled edges and the acoustic barrier layerextending beyond the profiled edges.

FIG. 29 schematically illustrates a side elevation view of the flooringproduct of FIG. 28.

FIG. 30 schematically illustrates a front elevation view of the flooringproduct of FIG. 28.

FIG. 31 schematically illustrates a perspective view of another flooringproduct with a pair of opposing profiled edges and the acoustic barrierlayer extending beyond the profiled edges.

FIG. 32 schematically illustrates a front elevation view of the flooringproduct of FIG. 31.

FIG. 33 schematically illustrates a front elevation view of two flooringproducts of FIG. 31 positioned adjacently such that the acoustic barrierlayer of the two flooring products are engaged.

FIG. 34 schematically illustrates a front elevation view of thearrangement of the pair of flooring products of FIG. 31 with a finishedflooring layer positioned on top of the pair of flooring products

FIG. 35 schematically illustrates a front elevation view of a flooringproduct with profiled edges, tongue and groove features, and theacoustic barrier layer extending beyond the tongue feature in into thegroove feature.

FIG. 36 schematically illustrates a front elevation view of two flooringproducts of FIG. 35 engaged via a tongue and groove system with theextending acoustic barrier layer of one flooring product engaged withthe other flooring product.

FIG. 37 schematically illustrates a front elevation view of thearrangement of the pair of flooring products of FIG. 35 with a finishedflooring layer positioned on top of the pair of flooring products.

FIG. 38 schematically illustrates a front elevation view of aceiling/floor assembly for a building.

FIG. 39 schematically illustrates a front elevation view of a flooringproduct and other layers for use with the ceiling/floor assembly of FIG.38.

FIG. 40 schematically illustrates a front elevation view of analternative arrangement of a flooring product and other layers for usewith the ceiling/floor assembly of FIG. 38.

FIG. 41 schematically illustrates one exemplary embodiment of anacoustic underlayment layer.

FIG. 42 schematically illustrates a front elevation view of anotheralternative arrangement of a flooring product and other layers for usewith the ceiling/floor assembly of FIG. 38.

DETAILED DESCRIPTION

The apparatus, systems, arrangements, and methods disclosed in thisdocument are described in detail by way of examples and with referenceto the figures. It will be appreciated that modifications to disclosedand described examples, arrangements, configurations, components,elements, apparatus, methods, materials, etc. can be made and may bedesired for a specific application. In this disclosure, anyidentification of specific techniques, arrangements, method, etc. areeither related to a specific example presented or are merely a generaldescription of such a technique, arrangement, method, etc.Identifications of specific details or examples are not intended to beand should not be construed as mandatory or limiting unless specificallydesignated as such. Selected examples of apparatus, arrangements, andmethods for flooring products and flooring assemblies that can provideacoustic barriers are hereinafter disclosed and described in detail withreference made to FIGS. 1-42.

Disclosed herein are flooring products and flooring assemblies for usein buildings. Flooring products are generally an assembly of multiplelayers of material. A flooring product can be manufactured, fabricated,or otherwise assembled in a manufacturing facility and shipped to aconstruction site for installation into a building. Alternatively,flooring products can be assembled at the construction site prior to oras the flooring product is installed into the building. As illustratedand designed herein, the arrangement of the multiple layers, thedimensions of the multiple layers, and features designed into theflooring products can be varied while remaining within the scope of theinventive flooring products described and claimed herein.

As will be described herein, a plurality of flooring products can bepositioned together or otherwise arranged to form a flooring assembly. Aflooring assembly as described herein can vary in size, shape, andapplication. Flooring assemblies can be arranged to form a floor for aportion of a room or form a complete floor for a room within a building.In another example, a flooring assembly can be arranged to span thecomplete width and length of a building to form a continuous floor for astory of a building. Such an example can include spanning the width andlength from each outside wall to the opposing outside wall. This is tosay that as a story of a building is constructed, the flooring assemblyis installed and subsequently the framing of the interior walls of thebuilding is built or otherwise erected on top of the flooring assembly,including interior walls that are either adjacent to or incorporatedinto the external walls.

As will be described in further detail herein, for flooring productsthat are placed adjacent to one another to form a continuous flooringassembly, the flooring products can include features that can engage orsecure one flooring product to one or more adjacent flooring products.Such features include, but are not limited to, tongue and groovefeatures formed along edges of the flooring products, lap joint featuresformed along edges of the flooring products, the extension of certainlayers beyond the edge of other layers of the flooring product, theprofiling of edges of the flooring products, and combinations thereof.

FIGS. 1 through 3 illustrate an exemplary flooring product 100, whichcan be assembled, fabricated, or otherwise used as disclosed herein.FIG. 1 illustrates a perspective view of the flooring product 100; FIG.2 illustrates an exploded perspective view of the flooring product 100,and FIG. 3 illustrates a cross-sectional view of the flooring product100 taken along the line shown in FIG. 1. The flooring product 100 canbe installed to form a floor during the construction of various types ofbuildings, including multi-story and multi-occupant buildings.

Generally, the flooring product 100 is installed as a “dry” product. A“dry” product refers to a product that generally includes componentsthat are already formed into a usable shape (i.e., already sized forinstallation or sized as to facilitated the cutting of components to anappropriate shape and size for installation) as opposed to includingcertain materials that are in a liquid state and require “pouring”on-site that dry, set, or cure over time into a final shape or form. Incertain embodiments, the flooring product 100 can include certaincomponents that are of “high density.” “High density” materials caninclude acoustic absorbing or deflecting properties that assist orfacilitate the controlling or channeling of acoustic energy.

Generally, the flooring product 100 as described herein is arranged sothat the flooring product 100 can form a barrier to the propagation ofacoustic energy. One method of determining whether a floor productsufficiently restricts the propagation of acoustic energy is bycomparing the performance of the product to the standards for acoustictesting in the construction industry. Such standards include protocolsthat determine ratings for the Sound Transmission Class (“STC”) andImpact Insulation Class (“IIC”) for a product or arrangement of multipleproducts. Exemplary procedures for determining STC ratings include ameasuring procedure conducted according to ASTM E90-09 (Standard TestMethod for Laboratory Measurement of Airborne Sound Transmission Loss ofBuilding Partitions and Elements) and calculating the rating accordingto ASTM E413-10. Exemplary procedures for determining IIC ratingsinclude a measuring procedure conducted according to ASTM E492-09(Standard Test Method for Laboratory Measurement of Impact SoundTransmission Through Floor-Ceiling Assemblies Using the Tapping Machine)and calculating the rating according to ASTM E989-10.

The flooring product 100 can comprise multiple layers of materials andcan be designed to be installed as a building is constructed orsubstantially remodeled. The flooring product 100 can be prefabricatedor manufactured off-site and transported on-site to a building underconstruction. For example, two or more layers of the flooring product100 can be secured together using, for example, adhesives, mechanicalfasteners or the like during a fabrication process and subsequentlydelivered to a construction site as a ready to install product.Alternatively, components or portions of the flooring product 100 can betransported on-site to a building under construction and two or morelayers can be secured together by workers prior to or duringinstallation of the flooring product 100 using, for example, adhesivesor mechanical fasteners.

As illustrated in FIG. 1, the flooring product 100 can includes a firstoriented strand board (“OSB”) layer 102, a second OSB layer 104; and anacoustic barrier layer 106 positioned between the first OSB layer 102and second OSB layer 104. In one example, the OSB layers 102, 104 can beapproximately ¾ inches in thickness. Although the first and second OSBlayers 102 and 104 are described as having a thickness of approximately¾ inches, for other examples, the thickness can range from ¼ to 1⅛inches. In one example, the first OSB layer 102 has a thickness ofapproximately ½ inches, and the second OSB layer 104 has a thickness ofapproximately ¾ inches. In one example, the acoustical barrier layer 106can be approximately 1/16 to ¼ inches in thickness. In one example, thefirst and second OSB layers 102 and 104 have a density of approximately0.024 pounds per cubic inch. It will be understood that the first andsecond OSB layers can include densities higher or lower than 0.024pounds per cubic inch, and that certain embodiments can include OSBlayers and an acoustic barrier layer that can be of a relatively highdensity.

In one embodiment, the OSB layers 102 and 104 can be manufactured in theform of panels from woods of relatively high densities. The OSB layers102 and 104 can be arranged so as to provide structural integrity forits use as flooring material and to withstand environmental conditionssuch as resisting absorption of moisture from rain and other sources,which can prevent or limit swelling, warping, and delamination of theOSB layers 102 and 104. It will further be understood that althoughexamples disclosed herein include the use of OSB layers, a flooringproduct can be comprised of other types of layers such as plywood,recycled plastic boards, plastic boards reinforced with fiberglass, andother engineered products.

A plurality of flooring products 100 can be arranged adjacent to oneanother to form a flooring assembly. FIG. 4 illustrates an exemplaryflooring assembly 108. The exemplary flooring assembly 108 is comprisedof an eight by four matrix of flooring products 100. Each flooringproduct 100 is abutted to each adjacent flooring product 100. This is tosay that the flooring products 100 are arranged such that the flooringassembly 108 is a generally continuous floor spanning the combinedlength and width of the flooring products 100. Although the flooringassembly 108 of FIG. 4 is illustrated as a matrix of eight by fourflooring products 100 of equal length and width, it will be understoodthat a flooring assembly 108 can be comprised of any number of flooringproducts 100, and such flooring products could vary in length and width.For example, if a flooring assembly 108 is constructed for a buildingthat is 50 feet in length and 50 feet in width with internal featuressuch as stairwells and plumbing, certain flooring products 100 can becut prior to assembly into a flooring assembly 108 to accommodate theprecise outer perimeter of the building and internal features.

A flooring assembly 108 can be arranged to span the complete width andlength of a building to form a continuous floor for a story of abuilding. In such an arrangement, the framing for the story can be builton top of the flooring assembly. FIG. 5 illustrates a plurality offlooring products 100 assembled to comprise a flooring assembly 108. Anumber of structural members 110 are built on top of the flooringassembly 108 to from the framing 112 that will define walls, doorways,etc. for a story of a building. As will be understood, the method ofinstalling a flooring assembly 108 followed by building the framing 112on top of the flooring assembly 108 can be used selectively for certainrooms of a building, used for certain stories of a building, or usedthroughout the entire building. For example, when a flooring assembly108 spans the width and length of each story of a building, all framing112 can be built on top of the flooring assembly 108, including allinterior walls throughout each story and walls adjacent to orincorporated into the external walls of the building.

Flooring products can be arranged to include features that facilitatesecuring or engaging one flooring product to adjacent flooring productsto form a flooring assembly. As illustrated in FIGS. 6-9, a flooringproduct 200 can be constructed of three layers—a first OSB layer 202, asecond OSB layer 204, and an acoustic barrier layer 206 sandwichedbetween the first and second OSB layers 202 and 204. In one example, theOSB layers 202 and 204 can be high density OSB layers. In one example,the acoustic barrier layer 206 can be a rubber layer. In other examples,the acoustic barrier layer 206 can be comprised of materials such aspolymers (including recycled plastics), cotton (and other similarmaterials), and binders and other additives. The acoustical barrierlayer 206 can be approximately 1/16 to ¼ inches in thickness. In oneexample, the acoustical barrier layer 206 is approximately ⅛ inches inthickness (i.e., approximately 3 millimeters). In additional examples,the acoustic barrier layer 206 can itself be comprised of multiplelayers.

The flooring product 200 includes a feature in the form of a tongue andgroove system. A tongue feature 208 can be formed along a first edge ofthe flooring product 200 and a groove feature 210 can be formed alongthe opposite edge of the flooring product 200. Such tongue 208 andgroove 210 features can form a connection system to facilitate theinstallation of the flooring product 200 during construction orremodeling of a building. The first OSB layer 202 can be approximately ¾inches in thickness and the second OSB layer 204 can be approximately ⅞inches in thickness. The acoustical barrier layer 206 can vary inthickness and density depending on the desired application. For example,the thickness of the acoustical barrier layer 206 can range from 1/16 to¼ inches. In other embodiments, the OSB layers 202 and 204 can range inthickness from ¼ to 1⅛ inches. FIG. 7 illustrates an exploded view ofthe flooring product 200, and FIG. 8 illustrates a cross-sectional viewof the flooring product 200 taken along the line illustrated in FIG. 6.In another example, the first OSB layer 202 can be approximately ½inches in thickness and the second OSB layer 204 can be approximately ¾inches in thickness.

In one embodiment, the flooring product 200 can be precut to facilitateefficient installation of a flooring assembly. For example, flooringproduct 200 can be precut into 2 foot by 8 foot sections. Such sectionsof the flooring product 200 are comparable in weight to 4 foot by 8 footsections of OSB board commonly used in construction. Typically a singleworkman can carry, position, and install the flooring product 200without assistance, thus, creating an efficient installation processes.In other embodiments, the flooring product 200 can be precut intoalternative sizes. For example, the flooring product 200 can be precutinto 4 foot by 8 foot sections or the flooring product 200 can be cut insections with widths anywhere between 2 foot and 4 foot.

As will be understood by those of ordinary skill in the art of buildingconstruction, the flooring product 200 as described herein andillustrated in FIGS. 6-9, along with other flooring products disclosedherein, can serve as a sub-decking and have substantial strength andstiffness. In addition to the substantial thicknesses of the first andsecond OSB layers 202 and 204, the tongue and groove systems furtherfacilitate stiffness. FIG. 9 schematically illustrates a cross-sectionalview of two flooring products 200 with the tongue 208 of one flooringproduct 200 engaged with the groove 210 of another flooring product 200.As will be understood, the tongue and groove system facilitates thesharing and transfer of weight and load forces between adjacent flooringproducts 200 thus, forming a system that is stiffer than comparableboards that are installed by simply abutted the boards next to eachother and securing to the underlying truss systems. Furthermore, theflooring product 200 itself and its tongue and groove system ofinstallation can provide continuity to the sound barrier properties ofthe flooring product 200.

Such strength and stiffness of the flooring product 200 can facilitatealteration to standard truss systems designed to support standardfloors. Typically, trusses are spaced 24 inches apart to supportanticipated loads applied to the floor. However, with the added strengthand stiffness of the flooring product 200, the trusses can be spaced atleast 32 inches apart. It will be understood that such an alteration inthe truss system can lower the cost of construction while maintainingthe structural integrity of the floors.

As illustrated in FIG. 10, additional layers can be added to theflooring product 200 to form a finished flooring product 212. In oneexample, a finished flooring product 212 (i.e., the portion above thetrusses) can be assembled from three layers: a top finished layer 214,an acoustic underlayment layer 216, and a flooring product 200. Theacoustic underlayment layer 216 can be positioned between the topfinished layer 214 and the flooring product 200. The term “finishedflooring product” is generally used to mean that the finished flooringproduct can be secured to previously installed trusses to complete asegment of flooring in a building.

The top finished layer 214 can be comprised of any number of materialsconsidered “finished flooring,” such as vinyl tile, hardwood,manufactured material, engineering flooring, etc. The top finished layer214 is designed and manufactured such that it can be directly exposed tothe occupants and furnishings of a room once construction has beencompleted. In one example, the top finished layer 214 is a luxury vinyltile (“LVT”). The LVT can be comprised of planks that “click together”or “loose lay” and, in one embodiment, can be approximately 1/16 to ¼inches in thickness. In one embodiment, the top finished layer 214 canbe approximately ⅛ inches (i.e., approximately 3 millimeters) inthickness. The top finished layer 214 can float or be held in place by avariety of adhesives or other such methods.

The acoustic underlayment layer 216 positioned between the top finishedlayer 214 and the flooring product 200 can be fabricated for any of anumber of materials such as, for example, rubber, a polymer, cotton, orother such materials. The acoustic underlayment layer 216 can beapproximately ⅛ to ¼ inches in thickness (i.e., approximately 3millimeters to 6 millimeters). In an alternative arrangement, thefinished flooring product 212 can include a pair of acousticunderlayment layers in place of the single acoustic underlayment 216illustrated in FIG. 10. When a pair of acoustic underlayment layers areincluded in the finished flooring product 212, each acousticunderlayment layer can be approximately 1/16 to ⅛ inches in thickness(i.e., approximately 1.5 millimeters to 3 millimeters). When a pair ofacoustic underlayment layers are included in the finished flooringassembly 212, the total thickness of the acoustic underlayment layerscan be approximately ⅛ to ¼ inches in thickness (i.e., approximately 3millimeters to 6 millimeters). Although the acoustic underlayment layers216 are described as each having a thickness of approximately 1/16 or ⅛inches, for other embodiments, the thickness can range from 1/16 to ¼inches. The acoustic underlayment layers 216 can be fabricated from anyof a number of materials such as, for example, rubber, a polymer,cotton, and other such materials. When a pair of acoustic underlaymentlayers is utilized, each can be fabricated for a different material.

The three layers of the finished flooring product 212 can be sold ordistributed as a kit, where the top finished layer 214, acousticunderlayment layer 216, and flooring product 200 are provided in sizesand arrangements to facilitate efficient and economical installation ofthe layers during construction or remodeling of a residential orcommercial building.

The flooring product 200, the finished flooring product 212, and othersimilar arrangements can be manufactured at a central location anddistributed and sold as a complete product to builders for use asflooring in homes and buildings. The components of the flooring product200 (a pair of OSB layers 202, 204 and an acoustic barrier layer 206) ora finished flooring product 212 (top finished layer 214, acousticunderlayment layer 216, and flooring product 200) can be securedtogether into the marketable product using a variety of methods. In oneexample, an adhesive can be applied to secure components together. Forexample, an adhesive can be used to secure an OSB layer to a firstsurface of an acoustic barrier layer, and additional adhesive can beapplied to secure another OSB layer to a second surface of the acousticbarrier layer. It will be understood that the surfaces of the OSB layersand the acoustic barrier layer can be prepared in advance of applyingthe adhesive. For example, the surfaces can be cleaned to remove dirt,debris, oils, etc. to better facilitate securing the OSB layers to theacoustic barrier layer. In another example, the surfaces can be“roughed” or “smoothed” to better facilitate the processes of securingtogether various layers.

In additional embodiments of the flooring product 200 and other similararrangements, the adhesive can be applied in a pattern that providesadequate adherence of the components, but also retains the naturalacoustic properties of the components and combination of the components.FIGS. 11A-11D illustrate exemplary adhesive patterns 302 applied to asurface 300 of an OSB layer, where an acoustic barrier layer willsubsequently be adhered to the surface 300 of the OSB layer. One designfactor to be considered in determining adhesive patterns is thatalthough the adhesive patterns are designed to adhere the OSB layer andan acoustic barrier layer, the adhesive pattern can be applied such thatthe adhesive does not overly fill too many pores or cavities present onthe surface of the OSB layer or acoustic barrier layer. The adhesivepatterns 302 illustrated in FIGS. 11A-11D are merely examples ofpossible patterns for securing an OSB layer to an acoustic barrierlayer. It will be understood that other adhesive patterns can be usedwith the embodiments disclosed herein. In one embodiment, the adhesivepattern is distributed across the surface of the OSB layer as torelatively evenly bear loads placed in the flooring product onceassembled. As previously discussed, adhesive can alternatively or inaddition be applied to the acoustic barrier layer, and such adhesive canbe applied in patters such as those illustrated in FIGS. 11A-11D or inother patterns.

It will also be understood that there are alternative methods ofsecuring together components to form a flooring product. For example,mechanical fasteners can be used to secure components together to form aflooring product. Such mechanical components include, among others,screws, rivets, nails, pegs, and so on.

Another embodiment of a flooring product 400 is schematicallyillustrated in cross-section in FIG. 12. The flooring product 400includes a tongue and groove system to facilitate the engagement with orsecuring of the flooring product 400 to other similarly arrangedflooring products 400. Similar to the previously described embodiment,the flooring product 400 can be constructed of three layers—a first OSBlayer 402, a second OSB layer 404, and an acoustic barrier layer 406sandwiched between the first and second OSB layers 402, 404. A tonguefeature 408 is formed along a first edge of the flooring product 400 anda groove feature 410 is formed along the opposite edge. As bestillustrated in FIG. 13, within the groove 410 of the flooring product400, a portion of the acoustic barrier layer 406 extends beyond thefirst and second OSB layers 402, 404 and into the groove 410 to form aprotrusion 412. In one embodiment, the protrusion 412 extendsapproximately 1/16 of an inch beyond the first and second OSB layers 402and 404. In another embodiment, the protrusion 412 extends approximately⅛ of an inch past beyond the first and second OSB layers 402 and 404. Itwill be understood that the extent that the protrusion extends beyondthe OSB layers can be increased or decreased as required.

FIG. 14 schematically illustrates a cross-sectional view of two flooringproducts 400 engaged via the tongue 408 and groove 410 features. Asillustrated in FIG. 14, when the two flooring products 400 are engaged,the protrusion 412 of one flooring product 400 engages the acousticbarrier layer 406 of the other flooring product 400. Such engagementincreases the continuity of acoustic barrier layers 406 across adjacentflooring products 400 after installation of the flooring products 400.Such continuity of the acoustic barrier layers 406 provides for betterand more consistent acoustic barrier properties for the installedflooring assembly.

The protrusion 412 can provide additional benefits for a flooringassembly comprised of adjacent flooring products 400. Whether due tobuilding code requirements, architectural design, or builder preference,flooring is often installed with a gap between subflooring components.Such a gap can provide sufficient room for expansion of the componentsand account for tolerances in the fabricating process of the components.As illustrated in FIG. 14, the protrusion 412 encourages the formationof a gap 414 between adjacently positioned flooring products 400. Such agap 414 can be proportional to the length the protrusion 412 extendsinto the groove 410. For example, in one embodiment, once assembled, theflooring system can include a gap of approximately ⅛ of an inch betweenadjacent flooring products 400. In another embodiment, once assembled,the flooring system can include a gap of approximately 1/16 of an inchbetween adjacent flooring products 400.

It will be understood that although the protrusion 412 is illustratedand described as extending into the groove 410, a flooring product canalso be designed and fabricated such that a protrusion extends beyondthe first and second OSB layers on the tongue side of the flooringproduct. It will further be understood that a flooring product can alsobe designed and fabricated such that a first protrusion extends beyondthe first and second OSB layers on the tongue side of the flooringprecut and a second protrusion extends beyond the first and second OSBlayer on the groove side of the flooring product.

FIGS. 15-17 illustrate another feature for engaging or securing aplurality of flooring products 500. The engagement features combine toform a lap joint. FIG. 15 illustrates a perspective view of a flooringproduct 500 designed to create a lap joint upon installation of adjacentflooring products 500 into a flooring assembly. FIG. 16 is across-sectional view of the flooring product 500 of FIG. 15. Theflooring product 500 can be constructed of three layers—a first OSBlayer 502, a second OSB layer 504, and an acoustic barrier layer 506sandwiched between the first and second OSB layers 502 and 504. A toplap portion 508 is formed along a first edge of the flooring product500, and a bottom lap portion 510 is formed along the opposite edge ofthe flooring product 500. As illustrated in FIG. 17, when flooringproducts 500 are positioned adjacently during installation, the top lapportion 508 along one edge of a flooring product 500 can engage with thebottom lap portion 510 of an adjacent flooring product 500. Theengagement of the top and bottom lap portions 508 and 510 can facilitatethe sharing and transfer of weight and load forces between adjacentflooring products 500 thus, forming a system that is stiffer thancomparable boards that are installed by simply abutted the boards nextto each other. Furthermore, the flooring product 500 itself and its lapjoint system of installation can provide continuity to the sound barrierproperties of the flooring product 500.

In another embodiment of a flooring product 600, as illustrated in FIG.18, the flooring product includes a first OSB layer 602, a second OSBlayer 604, and an acoustic barrier layer 606 arranged to form a top lapportion 608 along a first edge and bottom lap portion 610 along a secondedge. The acoustic barrier layer 606 includes a protrusion 612 thatextends beyond the first OSB layer 602 and into a bottom lap portion610. In one embodiment, the protrusion 612 extends approximately 1/16 ofan inch beyond the first OSB layer 602. In another embodiment, theprotrusion 612 extends approximately ⅛ of an inch past beyond the firstOSB layer 602.

FIG. 19 schematically illustrates a cross-sectional view of two flooringproducts 600 engaged via the lap joint features 608 and 610. Asillustrated in FIG. 19, when the two flooring products 600 are engaged,the protrusion 612 of one flooring product 600 engages the acousticbarrier layer 606 of the other flooring product 600. Such engagementincreases the continuity of acoustic barrier layers 606 across adjacentflooring products 600 after installation of the flooring products 600.Such continuity of the acoustic barrier layers 606 provides for betterand more consistent acoustic barrier properties for the installedflooring assembly.

The protrusion 612 can provide the additional benefit of encouraging agap between adjacent flooring products 600 in a flooring assembly. Asillustrated in FIG. 19, the protrusion 612 causes a gap 614 to formbetween adjacent floor products 600. Such a gap 614 can be proportionalto the length the protrusion 612 extends into the bottom lap portion610. For example, in one embodiment, once assembled, the flooringproducts 600 can include a gap of approximately ⅛ of an inch. In anotherembodiment, once assembled, the flooring products 600 can include a gapof approximately 1/16 of an inch.

It will be understood that although the protrusion 612 is illustratedand described as extending onto the bottom lap portion, a flooringproduct can also be designed and fabricated such that a protrusionextends onto the top lap portion of the flooring product. It willfurther be understood that a flooring product can also be designed andfabricated such that a first protrusion extends onto the top lap portionand a second protrusion extends onto the bottom lap portion of theflooring product.

Flooring products can be arranged with both tongue and groove featuresand lap joint features. For example, an eight foot by two foot flooringproduct can have a tongue feature formed along one eight foot edge and agroove feature formed along the opposite eight foot edge, and theflooring product can have a top lap feature formed along one two footedge and a bottom lap feature formed along the opposite two foot edge.When such flooring products are assembled into a flooring assembly,adjacent flooring products will be engaged by the tongue and groovefeatures along the eight foot edge and engaged by the lap joint featuresalong the two foot edge. Such an arrangement can provide a substantiallystiff and stable flooring assembly. The protrusion features of acousticbarrier layers as described herein can be included in such embodimentsto gain the benefits of such protrusions.

As illustrated in FIGS. 20-37, flooring products can be designed toinclude “profiled” edges. As used herein, “profiled edges” generallymeans that the edges of flooring products are not simply planer,stepped, or recessed (such as when an edge includes a tongue and groovefeature or a lap joint feature), but also include contours such asangled surfaces. A first example of a flooring product 700 with profilededges is illustrated in FIGS. 20-23. The flooring product 700 includes afirst OSB layer 702, a second OSB layer 704, and an acoustic barrierlayer 706 positioned between the first 702 and second 704 OSB layers.The acoustic barrier layer 706 is arranged such that a protrusion 712extends past the ends of the first OSB layer 702 and the second OSBlayer 704 (as best illustrated in FIG. 21). Two edges of the flooringproduct 700 are profiled edges 720. Each profiled edge 720 is formed byfeatures formed into the first OSB layer 702. In the embodiment of FIGS.20-23, the first OSB layer 702 of the flooring product 700 includes anupper vertical face 722, an angled face 724, and a lower vertical face726. The upper vertical face 722 extends from the top surface of thefirst OSB layer 702 downward until it intersects with the angled face724. The angled face 724 extends from the end of the upper vertical face722 downward until it intersects with the lower vertical face 726. Thelower vertical face 726 extends from the end of the angled face 724downward to the bottom surface of the first OSB layer 702. Asillustrated in FIGS. 20-23, the lower vertical face 726 is recessed ascompared to the upper vertical face 722, and the edge of the second OSBlayer 704 is generally in the same plane as the lower vertical face 726.

FIG. 22 illustrates a pair of engaged flooring products 700. When thepair of flooring products 700 is engaged, the respective protrusions 712from the pair of flooring products 700 come into contact, which resultsin a gap 730 between the flooring products 700 near the top portion ofthe flooring products 700 and another gap 732 between the flooringproducts 700 near the bottom portion of the flooring products 700. Inone example, the gap 730 near the top portion of the flooring products700 is about 1/16 of an inch in width, and the gap 732 near the bottomportion of the flooring products 700 is about 3/16 inches in width. FIG.23 illustrates the arrangement of the pair of flooring products 700 ofFIG. 22 with the addition of a top finished layer 734 on top of theengaged flooring products 700. Although the flooring product of FIGS.20-23 illustrate gaps (730, 732) of 1/16 and 3/16 inches, it will beunderstood that flooring products can be designed to result in gaps thatare either larger or smaller than those described and illustratedherein.

FIGS. 24-26 illustrate a flooring product 800 similar to the flooringproduct 700 of FIGS. 20-23, but with the addition of tongue and groovefeatures. FIG. 24 illustrates a front view of the flooring product 800,which is comprised of a first OSB layer 802, a second OSB layer 804, andan acoustic barrier layer 806 positioned between the first 802 andsecond 804 OSB layers. The flooring product 800 includes a tonguefeature 808 and a groove feature 810 similar to such features describedherein. The acoustic barrier layer 806 includes protrusions 812 thatextend into both the groove feature 810 and past the tongue feature 808.The flooring product 800 further includes a first profile edge 820 alongthe grooved edge of the flooring product 800 and a second profile edge821 along the tongue edge of the flooring product 800.

Along the grooved edge of the flooring product 800, the first profilededge 820 includes an upper vertical face 822, an angled face 824, and alower vertical face 826. The upper vertical face 822 extends from thetop surface of the first OSB layer 802 downward until it intersects withthe angled face 824. The angled face 824 extends from the end of theupper vertical face 822 downward until it intersects with the lowervertical face 826. The lower vertical face 826 extends from the end ofthe angled face 824 downward to the top surface of the groove feature810. Along the tongue edge of the flooring product 800, the secondprofiled edge 821 includes an upper vertical face 828, an angled face830, and a lower vertical face 832. The upper vertical face 828 extendsfrom the top surface of the first OSB layer 802 downward until itintersects with the angled face 830. The angled face 830 extends fromthe end of the upper vertical face 828 downward until it intersects withthe lower vertical face 832. The lower vertical face 832 extends fromthe end of the angled face 830 downward to the top surface of the tonguefeature 808. The lower vertical faces (826 and 832) are recessed ascompared to the upper vertical faces (822 and 828), and the edge of thesecond OSB layer 804 is generally in the same plane as the lowervertical faces (826 and 832).

FIG. 25 illustrates a pair of engaged flooring products 800. When thepair of flooring products 800 is engaged, the tongue feature 808 of oneflooring product 800 is inserted into the groove feature 810 of theother flooring product 800 until the protrusions 812 from the pair offlooring products 800 come into contact. When so engaged, a first gap840 is formed between the flooring products 800 near the top portion ofthe flooring products 800, a second gap 842 is formed between theflooring products 800 near the bottom portion of the flooring products800, and a third gap 844 is formed between the vertical surface of thetongue feature 808 and the vertical surface of the groove feature 810.In one example, the first gap 840 is about 1/16 of an inch in width, thesecond gap 842 is about 3/16 inches in width, and the third gap 844 isabout ⅛ of an inch in width. FIG. 26 illustrates the arrangement of thepair of flooring products 800 of FIG. 24 with the addition of a topfinished layer 846 on top of the engaged flooring products 800. Althoughthe flooring product of FIGS. 24-26 illustrate gaps (840, 842, and 844)of 1/16, ⅛, and 3/16 inches, it will be understood that flooringproducts can be designed to result in gaps that are either larger orsmall that those described and illustrated herein.

FIG. 27 illustrates another embodiment of a flooring product 900 similarto the flooring product 700 of FIGS. 20-23. The flooring product 900includes a first OSB layer 902, a second OSB layer 904, and an acousticbarrier layer 906 positioned between the first 902 and second 904 OSBlayers. Flooring product 900 differs in that the profiled edges 920 andthe protrusion 912 of the acoustic barrier layer 906 are along the“short” edge of the flooring product 900. This is to say that flooringproducts can be manufactured so that one pair of opposing edges arelonger than the other pair of opposing edges. As described herein, thedimensions of flooring products can include 8 foot by 4 foot productsand 8 foot by 2 foot products. As will be understood, in these twoexamples, the 8 foot edge would be considered the “long” edge and the 4foot edge and the 2 foot edge would be considered the “short” edge.Similar to the description of flooring product 700, flooring product 900includes a pair of opposing profiled edges 920, each with an uppervertical face 922, an angled face 924, and a lower vertical face 926.When a pair of flooring products 900 are engaged, a first gap is formednear the top of the flooring product 900 and a second gap is formed nearthe bottom of the flooring product 900. A flooring product 900 such asthat illustrated in FIG. 27 can also include tongue and groove featureson the profiled edges similar to the description of the flooring productillustrated in FIGS. 24-26.

FIG. 28 illustrates another embodiment of a flooring product 1000similar to the flooring product 700 of FIGS. 20-23 and the flooringproduct 900 of FIG. 27. The flooring product 1000 includes a first OSBlayer 1002, a second OSB layer 1004, and an acoustic barrier layer 1006positioned between the first 1002 and second 1004 OSB layers. Flooringproduct 1000 differs in that each of the four edges of the flooringproduct 1000 is a profiled edge 1020, and the protrusion 912 of theacoustic barrier layer 1006 extends along all four edges of the flooringproduct 1000. FIG. 29 illustrates a side elevation view of the long edgeof the flooring product 1000, and FIG. 30 illustrates a front elevationview of the short edge of the flooring product 1000.

Similar to the descriptions of flooring products 700 and 900, each edgeof the flooring product 1000 includes an upper vertical face 1022, anangled face 1024, and a lower vertical face 1026. When a pair offlooring products 1000 are engaged, a first gap is formed near the topof the flooring product 1000 and a second gap is formed near the bottomof the flooring product 1000. A flooring product 1000 such as thatillustrated in FIGS. 28-30 can also include tongue and groove featureson an opposing pair of profiled edges similar to the description of theflooring product illustrated in FIGS. 24-26, or on all four profilededges.

FIGS. 31-34 illustrates a flooring product 1100 with an alternativeprofiled edge. The flooring product 1100 includes a first OSB layer1102, a second OSB layer 1104, and an acoustic barrier layer 1106positioned between the first 1102 and second 1104 OSB layers. Theacoustic barrier layer 1106 is arranged such that a protrusion 1112extends past the ends of the first OSB layer 1102 and the second OSBlayer 1104 (as best illustrated in FIG. 32). Two edges of the flooringproduct 1100 are profiled edges 1120. Each profiled edge 1120 is formedby features formed into the first OSB layer 1102. The first OSB layer1102 of the flooring product 1100 includes an angled face 1122 and alower vertical face 1124. The angled face 1122 extends from the topsurface of the first OSB layer 1102 downward until it intersects withthe lower vertical face 1124. The lower vertical face 1124 extends fromthe end of the angled face 1122 downward to the bottom surface of thefirst OSB layer 1102. The lower vertical face 1124 is recessed ascompared to the angled face 1122, and the edge of the second OSB layer1104 is generally in the same plane as the lower vertical face 1126.

FIG. 33 illustrates a pair of engaged flooring products 1100. When thepair of flooring products 1100 is engaged, the respective protrusions1112 from the pair of flooring products 1100 come into contact, whichresults in a first gap 1130 between the flooring products 1100 near thetop portion of the flooring products 1100 and second gap 1132 betweenthe flooring products 1100 near the bottom portion of the flooringproducts 1100. In one example, the gap 1130 near the top portion of theflooring products 1100 is about 1/16 of an inch in width, and the gap1132 near the bottom portion of the flooring products 1100 is about 3/16inches in width. FIG. 34 illustrates the arrangement of the pair offlooring products 1100 of FIG. 31 with the addition of a top finishedlayer 1134 on top of the engaged flooring products 1100. Although theflooring product of FIGS. 31-34 illustrate gaps (1130, 1132) of 1/16 and3/16 inches, it will be understood that flooring products can bedesigned to result in gaps that are either larger or small that thosedescribed and illustrated herein.

FIGS. 35-37 illustrate a flooring product 1200 similar to the flooringproduct 1100 of FIGS. 31-35, but with the addition of tongue and groovefeatures. FIG. 35 illustrates a front view of the flooring product 1200,which is comprised of a first OSB layer 1202, a second OSB layer 1204,and an acoustic barrier layer 1206 positioned between the first 1202 andsecond 1204 OSB layers. The flooring product 1200 includes a tonguefeature 1208 and a groove feature 1210 similar to such featuresdescribed herein. The acoustic barrier layer 1206 includes protrusions1212 that extend into both the groove feature 1210 and past the tonguefeature 1208. The flooring product 1200 further includes a first profileedge 1220 along the grooved edge of the flooring product 1200 and asecond profile edge 1221 along the tongue edge of the flooring product1200.

Along the grooved edge of the flooring product 1200, the first profilededge 1220 includes an angled face 1222 and a lower vertical face 1224.The angled face 1222 extends from the top surface of the first OSB layer1202 downward until it intersects with the lower vertical face 1224. Thelower vertical face 1224 extends from the end of the angled face 1222downward to the top surface of the groove feature 1210. Along the tongueedge of the flooring product 1200, the second profiled edge 1221includes an angled face 1228 and a lower vertical face 1230. The angledface 1228 extends from the top surface of the first OSB layer 1202downward until it intersects with the lower vertical face 1230. Thelower vertical face 1230 extends from the end of the angled face 1230downward to the top surface of the tongue feature 1208. The lowervertical faces (1224 and 1230) are recessed as compared to the angledfaces (1222 and 1228), and the edge of the second OSB layer 1204 isgenerally in the same plane as the lower vertical faces (1224 and 1230).

FIG. 36 illustrates a pair of engaged flooring products 1200. When thepair of flooring products 1200 is engaged, the tongue feature 1208 ofone flooring product 1200 is inserted into the groove feature 1210 ofthe other flooring product 1200 until the protrusions 1212 from the pairof flooring products 1200 come into contact. When so engaged, a firstgap 1240 is formed between the flooring products 1200 near the topportion of the flooring products 1200, a second gap 1242 is formedbetween the flooring products 1200 near the bottom portion of theflooring products 1200, and a third gap 1244 is formed between thevertical surface of the tongue feature 1208 and the vertical surface ofthe groove feature 1210. In one example, the first gap 1240 is about1/16 of an inch in width, the second gap 1242 is about 3/16 inches inwidth, and the third gap 1244 is about ⅛ of an inch in width. FIG. 37illustrates the arrangement of the pair of flooring products 1200 ofFIG. 36 with the addition of a top finished layer 1246 on top of theengaged flooring products 1200. Although the flooring product of FIGS.35-37 illustrate gaps (1240, 1242, and 1244) of 1/16, ⅛, and 3/16inches, it will be understood that flooring products can be designed toresult in gaps that are either larger or smaller than those describedand illustrated herein.

The components of the flooring products can be individually shipped to aconstruction site for assembly in the field. Workmen in the field cansecure the component of the flooring product using adhesives, mechanicalcomponents, and other techniques. In another embodiment, adhesive can bepre-applied to one or more of the components, and the adhesives arecured in the field. In one example, a plurality of OSB layers andacoustic barrier layers can be transported to a construction site asindividual components. Workmen on site can secure two OSB layers and anacoustic barrier layer together to make a composite product similar tothe flooring product discussed herein. Such a composite product can beassembled as the workmen are installing the floor. Alternatively, suchcomposite layers can be assembled by workmen near the location of finalinstallation and the composite product can be installed as part of thefloor. In another example, large sheets of OSB and acoustic barriermaterial can be transported to a construction site. Such large sheetscan be cut into sizes applicable to the floor being installed. Once cutto appropriate size, two OSB layers and an acoustic barrier layer can beassembled into a composite layer for use in installing the floor.Alternatively, once cut to appropriate size, two OSB layers and anacoustic barrier layer can be assembled as the floor is installed.

Constructing buildings using flooring assemblies described herein canprovide substantial time and cost savings for builders as compared tousing traditional building materials and techniques. In traditionalbuilding techniques, workmen first complete the framing of each story ofa building, then subsequently return to each story to complete theflooring assembly. Such a technique includes hauling flooring materialsthrough a partially completed building such as up stairways the throughframed doorways and hallways. Such techniques also include the need forcustom cutting flooring materials to accommodate framed walls andinstalled features on each story of the building. When building with theflooring products disclosed herein, workmen can install a completeflooring assembly as each story of a building is completed. For example,workmen can install a plurality of four foot by eight foot flooringproducts to complete the flooring assembly on a given story of abuilding. The workmen subsequently erect the framing for that story ontop of the completed flooring assembly. Once framing is completed, theworkmen move to the next story without the need to return and completethe flooring. Such a technique limits the time consuming and laborintensive task of moving flooring materials in small quantities becausematerials can be moved in bulk and placed on each story as that story isbuilt out. In addition, because the flooring assembly system isinstalled before framing, the need for custom cutting of flooringmaterials is substantially limited.

The floor assemblies as described herein can provide for a substantialacoustic barrier to control the propagation of noise from one room toanother. Certain flooring products can include high density materials,which can provide for the absorption and/or deflection of acousticenergy directed at the described flooring assemblies. It will beappreciated that the materials described herein are generally materialsthat can be used as is (with the exception of cutting to size) duringconstruction. There is no need for the use of water or other “wet”elements or components, and, thus, there is no time needed for drying,curing or setting of the materials. Additionally, all the materialsdescribed herein can be generally used during construction regardless ofthe ambient temperature.

Flooring assemblies disclosed herein have been tested for use asacoustic barriers to determine the STC and IIC ratings for variousarrangements of flooring assemblies. Standard protocols were used. STCwas measured using ASTM E90-09 and calculated according to ASTM E413-10.IIC was measured using ASTM E492-09 and calculated according to ASTME989-10. Generally, a score of 50 in a laboratory setting and a score of45 for in-filed testing under either the STC or IIC protocol meetslocal, state, and federal building regulations. Table 1 includesexemplary arrangements that have achieved a score of 50 or higher underthe protocols.

TABLE 1 Layer 1 Layer 2 Layer 3 Layer 4 Result Notes  1 Cotton UL 3/4″OSB 5 mm rubber 3/4″ OSB 50 STC  2 vinyl flooring 3/4″ OSB 2 mm rubber3/4″ OSB 52 IIC  3 vinyl plank 12.7 mm OSB 2 mm rubber 18.3 mm OSB 61STC  4 vinyl plank 12.7 mm OSB 2 mm rubber 18.3 mm OSB 58 IIC  5 vinylplank 18.3 mm OSB 2 mm rubber 18.3 mm OSB 60 STC  6 vinyl plank 12.7 mmOSB 2 mm rubber 18.3 mm OSB 55 IIC  7 vinyl plank 23/32″ OSB 2 mm rubber23/32″ OSB 62 STC Secured with screws  8 vinyl plank 23/32″ OSB 2 mmrubber 23/32″ OSB 56 IIC Secured with screws  9 vinyl plank 23/32″ OSB 2mm rubber 23/32″ OSB 63 STC Layers 2, 3, and 4 adhered together 10 vinylplank 23/32″ OSB 2 mm rubber 23/32″ OSB 57 IIC Layers 2, 3, and 4adhered together 11 Engineering 23/32″ OSB 2 mm rubber 23/32″ OSB 62 STCLayers 2, 3, and 4 wood adhered together 12 Engineering 23/32″ OSB 2 mmrubber 23/32″ OSB 59 IIC Layers 2, 3, and 4 wood adhered together

FIG. 38 illustrates an exemplary ceiling/floor assembly system 1300 fora building. FIG. 39 illustrates a detailed portion of the ceiling/floorassembly system 1300, and FIG. 40 illustrates a detailed portion of analternative ceiling/floor assembly system. The ceiling/floor assemblysystem 1300 includes flooring products and additional components. Itwill be understood that a “ceiling/floor assembly system” can includecomponents of the ceiling of the story below the story where theceiling/floor assembly system 1300 is installed, which includes anytruss or joist system that connects or spans the floor and ceiling, aswell as a floor for the story for which the ceiling/floor assemblysystem is installed.

Portions of the ceiling/floor assembly system 1300 can be prefabricatedoff-site and transported on-site to a building under construction. Forexample, two or more layers of the ceiling/floor assembly system 1300can be secured together using, for example, adhesives, mechanicalfasteners or the like during a fabrication process and be delivered to aconstruction site as a ready to install assembly. Alternatively,portions or all of the ceiling/floor assembly system 1300 can betransported on-site to a building under construction and two or morelayers can be secured together by workers prior to or duringinstallation of the ceiling/floor assembly system 1300 using, forexample, adhesives or mechanical fasteners.

As illustrated in FIG. 38, the ceiling/floor assembly system 1300includes a top finished layer 1310 that can be exposed to the occupantsof a room once construction has been completed. Similar to previousdescription, the top finished layer 1210 can be comprised of any numberof materials considered “finished flooring,” such as vinyl tile,hardwood, manufactured material, engineering flooring, etc. In oneexample, the top finished layer 1310 is a luxury vinyl tile (“LVT”). TheLVT can be approximately 1/16 to ¼ inches in thickness. In oneembodiment, the top finished layer 1310 can be approximately ⅛ inches(i.e., approximately 3 millimeters) in thickness. In one example, thetop finished layer 1310 can float or be held in place by a variety ofadhesives or other such methods.

As illustrated in FIG. 39, the ceiling/floor assembly system 1300includes an acoustic underlayment layer 1320 below the top finishedlayer 1310. The underlayment layer 1320 can be fabricated for any of anumber of materials such as, for example, rubber, a polymer, cotton, orother such materials. The underlayment layer 1320 can be approximately ⅛to ¼ inches in thickness (i.e., approximately 3 millimeters to 6millimeters). In an alternative arrangement, as illustrated in FIG. 40,the ceiling/floor assembly system 1300 can include a pair of acousticunderlayment layers 1320A and 1320B. The acoustic underlayment layers1320A and 1320B can each be approximately ⅛ or 3/32 inches in thickness(i.e., approximately 3 millimeters or 4 millimeters). When a pair ofacoustic underlayment layers 1320A and 1320B are included in theceiling/floor assembly system 1300, the total thickness of the acousticunderlayment layers 1320A and 1320B can be approximately ¼ inches inthickness (i.e., approximately 6 millimeters). Although the acousticunderlayment layers 1320A and 1320B are described as each having athickness of approximately ⅛ or 3/32 inches, for other embodiments, thethickness can range from 1/16 to ¼ inches. The underlayment layers 1320Aand 1320B can be fabricated for any of a number of materials such as,for example, rubber, a polymer, cotton, and other such materials. Theunderlayment layers 1320A and 1320B can each be fabricated for differentmaterials.

The ceiling/floor assembly system 1300 can include a first OSB layer1330 below the acoustic underlayment layer 1320. The first OSB layer1330 can be approximately ¾ inches in thickness. The ceiling/floorassembly system 1300 includes an additional acoustical barrier layer1340 below the first OSB layer 1330. The acoustical barrier layer 1340can be approximately 1/16 to ¼ inches in thickness. In one embodiment,the acoustical barrier layer 1340 is approximately ⅛ inches in thickness(i.e., approximately 3 millimeters). The ceiling/floor assembly system1300 includes a second OSB layer 1350 below the acoustical barrier layer1340. The second OSB layer 1350 can be approximately ¾ inches inthickness. Although the first 1330 and second 1350 OSB layers aredescribed as having a thickness of approximately ¾ inches, for otherembodiments, the thickness can range from ¼ to 1⅛ inches. In oneembodiment, the first OSB layer 1330 has a thickness of approximately ½inches and second OSB layer 1350 has a thickness of approximately ¾inches. In one embodiment, the OSB layers 1330 and 1350 have a densityof approximately 0.024 pounds per cubic inch.

The layers described above (top finished layer 1310, acousticunderlayment layer 1320, first OSB layer 1330, the additional acousticalbarrier layer 1340, and the second OSB layer 1350) generally form asubfloor or sub-deck 1360 of a room or apartment in a building. Asillustrated in FIG. 38, a series of trusses 1370 or other similar loadbearing and structural components can connect the subfloor 1360 to theceiling 1380 of the room or apartment located one story below. Thetrusses 1370 can be arranged to accommodate any reasonable distancebetween the subfloor 1360 and ceiling 1380.

The ceiling 1380 includes a gypsum wall board layer 1390. The gypsumwall board layer 1390 can be approximately ⅝ inches in thickness. Abovethe gypsum wall board layer 1390 is a series of resilient channels 1400.Above the resilient channels 1400 is an insulating material 1410. Theinsulating material 1410 can include properties for insulating againstacoustic energy such as air-borne and impact noises. The insulatingmaterial 1410 can be constructed of a mineral wall material and in oneexample can be 3½ inches in thickness.

FIG. 41 illustrates an exemplary embodiment of another acousticunderlayment layer 1500, which can be used in place of previouslydescribed acoustic underlayment layers 1320 (also 1320A and 1320B). Theacoustic underlayment layer 1500 includes a first layer 1502 and asecond layer 1504. The first layer 1502 can be made from rubber and thesecond layer 1504 can be made from cotton. In one embodiment, the firstlayer 1502 is made from recycled materials, such as used automobiletires. In one embodiment, the second layer 1504 can also be made fromrecycled materials such as used denim. Although the first and secondlayers 1502 and 1504 are described as manufactured from recycledmaterials, the first and second layers 1502 and 1504 can also bemanufactured from virgin or other non-recycled material. The first layer1502 and the second layer 1504 can be secured to one another to form theacoustic underlayment layer 1500 by an adhesive such as contact glue orother such compounds. It will be understood that the materials asdescribed for underlayment 1500 can be used to fabricate underlaymentlayers 1320, 1320A, and 1320B.

As illustrated in FIG. 42, once the acoustic underlayment layer 1500 isformed, it can be used to construct the “flooring” portion of aceiling/floor assembly system similar to the ceiling/floor assemblysystem 1300 illustrated in FIGS. 38, 39, and 40, where the acousticunderlayment layer 1500 of FIG. 41 is used in placed of the acousticunderlayment layer 1320 of FIGS. 38 and 39 (or the pair of acousticalunderlayment layers 1320A and 1320B of FIG. 40). In one embodiment, theoverall thickness of the acoustic underlayment layer 1500 isapproximately ¼ inches (approximately 6 millimeters), with the firstlayer 1502 approximately ⅛ inches thick (i.e., approximately 3millimeters) and the second layer approximately 3/32 inches in thickness(i.e., approximately 4 millimeters). For other embodiments, thethickness of the first layer 1502 can range from 1/16 to ¼ inches andthe thickness of the second layer 1504 can range from 1/16 to ½ inches.

The density of the acoustic underlayment layers 1320, 1320A, 1320B, and1500 can be adjusted based on the level of acoustic absorption anddeflection desired in the application of a ceiling/floor assemblysystem. Furthermore, the density of the acoustic underlayment layers1320, 1320A, 1320B, and 1500 can also be adjusted so that the stiffnessof the acoustic underlayment layers 1320, 1320A, 1320B, and 1500 issufficient to support the top finished layer 1310. For example, if thetop finished layer 1310 is made of long slats of hardwood or engineeredhardwood flooring with a “tongue and groove” connecting system, theacoustic underlayment layer 1500 can be arranged to have sufficientstiffness such that the top finished layer 1310 does not flex to thepoint that the slats separate. One method of stiffening the acousticunderlayment layers with multiple layers, such as underlayment layers1320A, 1320B and underlayment layer 1500 (comprised of layers 1502 and1504) is for a first layer 1320A or 1502 to have a relatively highdensity. One method of achieving a relatively high density is to formthe first layer 1320A or 1502 from tightly compacted, finely groundrecycled tires. In one embodiment, the density of the first layer 1320Aor 1502 is approximately 0.72 g/cm³ as measured according to ASTM D297.Such principles also apply to acoustic barrier layers described herein.

The foregoing description of examples has been presented for purposes ofillustration and description. It is not intended to be exhaustive orlimiting to the forms described. Numerous modifications are possible inlight of the above teachings. Some of those modifications have beendiscussed, and others will be understood by those skilled in the art.The examples were chosen and described in order to best illustrateprinciples of various examples as are suited to particular usescontemplated. The scope is, of course, not limited to the examples setforth herein, but can be employed in any number of applications andequivalent devices by those of ordinary skill in the art.

We claim:
 1. A flooring product comprising: a first oriented strandboard including a first surface and a second surface; a second orientedstrand board including a first surface and a second surface; and anacoustic barrier layer including a first surface and a second surfacepositioned between the first oriented strand board and the secondoriented strand board; wherein the first surface of the acoustic barrierlayer is secured to the first surface of the first oriented strand boardby a discontinuous application of adhesive material and the secondsurface of the acoustic barrier layer is secured to the first surface ofthe second oriented strand board by a discontinuous application ofadhesive material.
 2. The flooring product of claim 1, wherein theapplication of adhesive material includes a plurality of generallycircular areas of adhesive material.
 3. The flooring product of claim 1,wherein the application of adhesive material includes a plurality ofgenerally linear areas of adhesive material.
 4. The flooring product ofclaim 1, wherein the application of adhesive material includes a atleast one generally non-linear area of adhesive material.
 5. Theflooring product of claim 1, wherein: a first edge of the first orientedstrand board includes a stepped section along the first edge; a secondedge of the first oriented strand board, opposite the first edge of thefirst oriented strand board, includes a recessed section along thesecond edge; a first edge of the second oriented strand board includes astepped section along the first edge; a second edge of the secondoriented strand board, opposite the first edge of the second orientedstrand board, includes a recessed section along the second edge;wherein, upon the securing of the acoustic barrier layer to the firstand second oriented strand boards, the stepped section of the firstoriented strand board and the stepped section of the second orientedstrand board are arranged to form a tongue; and wherein, upon thesecuring of the acoustic barrier layer to the first and second orientedstrand boards, the recessed section of the first oriented strand boardand the recessed section of the second oriented strand board arearranged to form a groove.
 6. The flooring product of claim 5, wherein aportion of the acoustic barrier layer protrudes into the groove.
 7. Theflooring product of claim 1, wherein: a first edge of the first orientedstrand board is a first profiled edge, and the second edge of the firstoriented strand board is a second profiled edge.
 8. The flooring productof claim 7, wherein the profile of the first profiled edge of the firstoriented strand board is generally the same as the profile of the secondprofiled edge of the first oriented strand board.
 9. The flooringproduct of claim 1, further comprising: an acoustic underlayment layerpositioned adjacent to the second surface of the first oriented strandboard; and a finished flooring layer positioned adjacent to theunderlayment layer.
 10. The flooring product of claim 9, wherein theacoustic underlayment layer includes a first portion with a firstacoustic absorbing property and a second portion with a second acousticabsorbing property.
 11. The flooring product of claim 1, wherein thefirst oriented strand board and second oriented strand board arecomprised of high density material.
 12. The flooring product of claim 1,wherein the first and second oriented strand boards are each betweenapproximately 0.25 inches and 1.125 inches in thickness.
 13. Theflooring product of claim 1, wherein the acoustic barrier layer isbetween approximately 0.0625 inches and 0.25 inches in thickness. 14.The flooring product of claim 1, wherein the density of the acousticbarrier layer is approximately 0.72 grams/cm³.
 15. The flooring productof claim 1, wherein the acoustic barrier layer is manufactured fromgranulized rubber.
 16. The flooring product of claim 1, furthercomprising a truss system; wherein the second surface of the secondoriented strand board is positioned adjacent to the truss system. 17.The flooring product of claim 1, wherein the flooring product meets orexceeds a rating of 50 when tested by the standards of the SoundTransmission Class test under laboratory conditions.
 18. The flooringproduct of claim 1, wherein the flooring product meets or exceeds arating of 50 when tested by the standards of the Impact Insulation Classtest under laboratory conditions.
 19. A flooring product comprising: afirst oriented strand board; a second oriented strand board; and anacoustic barrier layer positioned between the first oriented strandboard and the second oriented strand board; wherein the flooring productmeets or exceeds a rating of 50 when tested by the standards of theSound Transmission Class test under laboratory conditions and meets orexceeds a rating of 50 when tested by the standards of the ImpactInsulation Class test under laboratory conditions.
 20. The flooringproduct of claim 19, wherein the acoustic barrier has a first surfaceand a second surface, and the first surface of the acoustic barrierlayer is secured to a first surface of the first oriented strand boardby a discontinuous application of adhesive material and the secondsurface of the acoustic barrier layer is secured to a first surface ofthe second oriented strand board by a discontinuous application ofadhesive material.